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NadiR

1,028 posts

34 months

[news] 
Wednesday 22nd February 2012 quote quote all
Probably the most bonkers project I've seen on PH. You got a Peugeot and you're adding on some BMW, some Nissan, and probably more car manufacturers to come! Absolute madness (in a good way).

davetibbs

Original Poster:

136 posts

33 months

[news] 
Wednesday 22nd February 2012 quote quote all
NotDave said:
Makes sense to me, as the whole frame would have strength, and line up to roof. Scuttle could be adapted to suit yes
It's a good idea, but the whole frame wasn't available. I'll probably give it a good go with the bits I've got and the 405 windscreen frame and see if I can succeed with that. If not I'll hunt down an entire E46 windscreen frame.

NotDave

20,951 posts

44 months

[news] 
Thursday 23rd February 2012 quote quote all
davetibbs said:
It's a good idea, but the whole frame wasn't available. I'll probably give it a good go with the bits I've got and the 405 windscreen frame and see if I can succeed with that. If not I'll hunt down an entire E46 windscreen frame.
BMW scrapyard, angle grinder. Off you go?


Can't see there being much "demand" for that part, as most are gonna be crushed with the rest of the shell ain't they?

davetibbs

Original Poster:

136 posts

33 months

[news] 
Thursday 23rd February 2012 quote quote all
True enough. However, I forsee "difficulties" with getting the bottom curve of the E46 windscreen frame joined to the 405 bulkhead - it could actually be a lot more work than the way I've planned. Since I've already got the windscreen top I'll probably stick with the "strengthened 405 frame" plan for now, and if it doesn't work I can lob it off and try and use a full E46 frame.

NotDave

20,951 posts

44 months

[news] 
Thursday 23rd February 2012 quote quote all
Fair point.


How many additional tonnes of welded in metal are being added?
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davetibbs

Original Poster:

136 posts

33 months

[news] 
Thursday 23rd February 2012 quote quote all
A lot! As I understand it, it's not uncommon for factory convertibles to have an extra 200kgs of additional weight over the saloon/coupe model. I'll probably end up with quite a bit more than that. In fairness I haven't weighed the extra metal I've added as I've prioritised chassis strength over weight saving, with the idea that if it affects performance too drastically, my engine isn't powerful enough. I might take the completed car onto a weighbridge out of interest though.

NotDave

20,951 posts

44 months

[news] 
Thursday 23rd February 2012 quote quote all
If it's too heavy, just add more power rofl


You strengthening sills/door appetures (sp?) and such?

davetibbs

Original Poster:

136 posts

33 months

[news] 
Thursday 23rd February 2012 quote quote all
Yes, the sills already have a lot of additional strengthening (essentially box section) both inside and outside the car. The door apertures will be strengthened at the hinge end with the same strengthening for the windscreen (to provide support for longer - and therefore heavier - doors), and at the latch end to restore rigidity to the (shortened) B pillars which will also double up as support for the roof. I'll try and get some drawings up at some point to highlight where all the strengthening has gone.

NotDave

20,951 posts

44 months

[news] 
Thursday 23rd February 2012 quote quote all
Makes sense.

Any "under chassis bracing"...... I.e. E36 cabriolets had that X brace that bolted on?

Plus, shock to shock OMP type bracing?

davetibbs

Original Poster:

136 posts

33 months

[news] 
Thursday 23rd February 2012 quote quote all
Yep, the list above isn't exhaustive. There's a front strut brace (just bolt-on though), and a welded cross-brace in the rear behind the seat. Plus I'm currently beefing up the front and rear chassis legs.

I'm considering an X-brace but not sure of the best way of approaching it at the moment.

NotDave

20,951 posts

44 months

[news] 
Thursday 23rd February 2012 quote quote all
Cool. smile


X brace...... BMW ones are good, BUT fetch a premium. So I'd be tempted if you have the skills, to fab one up

doogz

23,381 posts

74 months

[news] 
Thursday 23rd February 2012 quote quote all
Amazing project! I love old Peugeots as well.

Whitean3

1,524 posts

85 months

[news] 
Thursday 23rd February 2012 quote quote all
When I first skim read the OP, I thought we were about to see a Peugeot 406 coupe to cabrio conversion (which could look pretty damn good). Then I saw it was a 4-door 405.- now that is a LOT of work! Seem to remeber one of the Max Power type mags featured a 4 to 2 door conversion on a Pug 306 saloon a few years back...

rhinochopig

17,100 posts

85 months

[news] 
Thursday 23rd February 2012 quote quote all
So does anyone else have mental image of a cabrio version of this?


davetibbs

Original Poster:

136 posts

33 months

[news] 
Thursday 23rd February 2012 quote quote all
Whitean3 said:
When I first skim read the OP, I thought we were about to see a Peugeot 406 coupe to cabrio conversion (which could look pretty damn good). Then I saw it was a 4-door 405.- now that is a LOT of work! Seem to remeber one of the Max Power type mags featured a 4 to 2 door conversion on a Pug 306 saloon a few years back...
I actually had a 406 coupe which I was tempted to do the conversion on, but couldn't bring myself to chop that beautiful body so chose the 405 instead. The irony is that it's now being broken for parts in my back garden rolleyes Maybe I could do it in the future smile

I remember the 2 door 306 saloon - it was an Ecosse job I think, I suspect they used the parts necessary (such as rear wings) from a 3 door hatch, but I have no such cheats available frown

BDR529

3,329 posts

61 months

[news] 
Thursday 23rd February 2012 quote quote all
You Sir are nuts. biggrin

richard300

1,004 posts

96 months

[news] 
Thursday 23rd February 2012 quote quote all
This thread has got me thinking about finding a 405 Mi-16 as a bit of a retro daily. Hopefully though when i head to the classifieds there are either non for sale, or they have hit that 'inflated price' retro bubble. As i already have to many cars and not enough room.

davetibbs

Original Poster:

136 posts

33 months

[news] 
Monday 5th March 2012 quote quote all
Just a small update:

Making the mounting brackets for the airbags



Cleaning suspension turret mounting plates (still needs a polish)


Wishbones painted with all new bushes


Adapting Spax PSX Adjustable shocks to fit airbags:

First, cut off spring mounting cup


Then, strip paint


and weld on coilover conversion tube:



Once welds are tidied up and bottom mounts are finished, the shocks can be painted.

I also started stripping 406 Coupe Brembo calipers for seal replacement and painting:


And ordered some badge lettering on a whim getmecoat

mwstewart

2,267 posts

75 months

[news] 
Monday 5th March 2012 quote quote all
Interesting project. Did you weld those sleeves on with the damper assembly still inside?

davetibbs

Original Poster:

136 posts

33 months

[news] 
Monday 5th March 2012 quote quote all
mwstewart said:
Interesting project. Did you weld those sleeves on with the damper assembly still inside?
Yes. I was in two minds whether to do so but didn't really fancy dismantling the shocks, which would have presumably required them to be regassed afterwards. As such we were very careful with the welding that it didn't get too hot, and I figure the fact that they still move afterwards means that they'll probably be fine smile
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